Salt water drilling mud and method

Abstract

A salt water drilling mud comprising a mixture salt water, a solid phase such as pre-hydrated bentonite, attapulgite, sepiolite, and extended bentonite, among others and optionally a synthetic oil, which is mixed with at least one of five different modules. A first module contains caustic, a natural wax and a natural thinner. A second module contains components of the first module and an alkali metal aluminate prepared by reacting the first module with aluminum metal. A third module contains the components of the first module and an alkali metal phosphate and/or alkali metal silicate. A fourth module contains the components of the first module, a saturated or unsaturated carboxylic acid source, a surfactant, and a preservative. The fifth module contains a combination of the first, third and fourth modules.

What is claimed is:  
     
       1. A salt water drilling mud comprising salt water, a solid phase selected from the group consisting of pre-hydrated bentonite, attapulgite, sepiolite, vermiculite, 2:1 clays, 2:1:1 clays and extended bentonite, optionally a synthetic oil, and at least one of the following drilling fluid additive modules 1)-5): 
       1) an alkaline first module comprising a source of caustic, a natural wax, and a natural thinner;  
       2) a second module prepared by reacting aluminum metal with the components of said alkaline first module thereby forming a soluble alkali metal aluminate;  
       3) a third module containing said components of said first module in combination with at least one of an alkali metal phosphate, borate and sodium silicate;  
       4) a fourth module containing said components of said first module in combination with a saturated or unsaturated carboxylic acid source, a surfactant, and a preservative; and/or  
       5) a fifth module containing said components of said first module in combination with a saturated or unsaturated carboxylic acid source, a surfactant, a preservative, and at least one of an alkali metal phosphate, borate and sodium silicate;  
       wherein said third, fourth and fifth modules can be used for simultaneously thinning and increasing the lubricity of a drilling mud and penetrating the earth material capillaries, and said second module can be used for thickening the drilling mud.  
     
     
       2. The drilling mud of claim  1 , further comprising a fluid loss control additive. 
     
     
       3. The drilling mud of claim  2 , wherein the fluid loss control additive is selected from the group consisting of carboxymethyl cellulose, carboxyethyl cellulose, lignite, xanthan gum, starch, sodium polyacrylamide, hydroxy methyl cellulose, hydroxy ethyl cellulose, guar gum, hydroxy propyl guar and hydroxy ethyl guar. 
     
     
       4. The drilling mud of claim  1 , wherein the salt water is saturated. 
     
     
       5. The drilling mud of claim  1 , comprising saturated salt water, a solid phase selected from the group consisting of pre-hydrated bentonite, attapulgite, sepiolite, and extended bentonite, a mixed metal hydroxide, optionally a synthetic oil, and a drilling fluid comprising a source of caustic, a natural wax, a natural thinner, a saturated or unsaturated carboxylic acid source, a surfactant, a preservative, and at least one of an alkali metal phosphate, borate and sodium silicate. 
     
     
       6. The drilling mud of claim  5 , wherein the alkali metal phosphate is selected from the group consisting of mono-, di-, and tri-sodium phosphate, mono-, di-, and tri-potassium phosphate, and mono-, di-, and tri-cesium phosphate, sodium acid pyrophosphate and the borate is a boriborate. 
     
     
       7. The drilling mud of claim  1 , comprising up to about 2% by volume of one or more of the modules 1)-5). 
     
     
       8. The drilling mud of claim  7 , wherein the salt water is saturated and the salt in the water is an alkaline earth metal salt or alkali metal salt. 
     
     
       9. The drilling mud of claim  8 , wherein the drilling mud comprises module 5 present in an amount of 0.25% to about 2.0% of the drilling mud. 
     
     
       10. The drilling mud of claim  8 , wherein the synthetic oil is present and is a C 8 , C 10 , C 12  polyalphaolefin or a carboxylic acid ester. 
     
     
       11. A drilling method comprising injecting the salt water drilling mud according to claim  1  into a borehole and drilling into the earth. 
     
     
       12. A method of reducing the formation of hydrates in a salt water drilling mud comprising adding to the salt water based drilling mud at least one of the following drilling fluid additive modules 1)-5): 
       1) an alkaline first module comprising a source of caustic, a natural wax, and a natural thinner;  
       2) a second module prepared by reacting aluminum metal with the components of said alkaline first module thereby forming a soluble alkali metal aluminate;  
       3) a third module containing said components of said first module in combination with at least one of an alkali metal phosphate, borate and sodium silicate;  
       4) a fourth module containing said components of said first module in combination with a saturated or unsaturated carboxylic acid source, a surfactant, and a preservative; and/or  
       5) a fifth module containing said components of said first module in combination with a saturated or unsaturated carboxylic acid source, a surfactant, a preservative, and at least one of an alkali metal phosphate, borate and sodium silicate.  
     
     
       13. A salt water drilling mud comprising salt water, a solid phase selected from the group consisting of pre-hydrated bentonite, attapulgite, sepiolite, vermiculite, 2:1 clays, 2:1:1 clays and extended bentonite, optionally a synthetic oil, and at least one of the following drilling fluid additive modules 1)-5): 
       1) an alkaline first module comprising a source of caustic, a natural wax, a natural thinner, glycerol, and an acid selected from phosphoric acid, boric acid or mixture thereof;  
       2) a second module prepared by reacting an aluminum metal with the components of said alkaline first module thereby forming a soluble alkali metal aluminate;  
       3) a third module comprising said components of said first module in combination with at least one of an alkali metal phosphate, borate and sodium silicate;  
       4) a fourth module comprising said components of said first module in combination with a saturated or unsaturated carboxylic acid source; and/or  
       5) a fifth module comprising said components of said first module in combination with a saturated or unsaturated carboxylic acid source, and at least one of an alkali metal phosphate, borate and sodium silicate,  
       wherein said third, fourth and fifth modules can be used for simultaneously thinning and increasing the lubricity of a drilling mud thus improving penetration of a drill bit, and said second module can be used for thickening a drilling mud.  
     
     
       14. A salt water drilling mud comprising a mud component comprising saturated salt water, a solid phase selected from the group consisting of pre-hydrated bentonite, attapulgite, sepiolite, and extended bentonite, a mixed metal hydroxide and optionally a synthetic oil; and a drilling fluid comprising a caustic source, a natural wax, a natural thinner, glycerol, and an acid selected from phosphoric acid, boric acid or mixtures thereof. 
     
     
       15. The drilling mud of claim  14 , wherein the drilling fluid further comprises a gel . 
     
     
       16. The drilling mud of claim  14 , wherein the drilling fluid further comprises a fluid loss additive selected from the group consisting of carboxymethyl cellulose, carboxyethyl cellulose, lignite, xanthan gum, starch, sodium polyacrylamide, hydroxy methyl cellulose, hydroxy ethyl cellulose, guar gum, hydroxy propyl guar and hydroxy ethyl guar. 
     
     
       17. The drilling mud of claim  14 , wherein the drilling fluid further comprises an aluminum metal which reacts with the other components of the drilling fluid to form a soluble alkali metal aluminate. 
     
     
       18. The drilling mud of claim  17 , wherein the drilling fluid further comprises a gel. 
     
     
       19. The drilling mud of claim  17 , wherein the drilling fluid further comprises a fluid loss additive selected from the group consisting of carboxymethyl cellulose, carboxyethyl cellulose, lignite, xanthan gum, starch, sodium polyacrylamide, hydroxy methyl cellulose, hydroxy ethyl cellulose, guar gum, hydroxy propyl guar and hydroxy ethyl guar. 
     
     
       20. The drilling mud of claim  14 , wherein the drilling fluid further comprises at least one of an alkali metal phosphate, borate and sodium silicate. 
     
     
       21. The drilling mud of claim  20 , wherein the drilling fluid further comprises a gel. 
     
     
       22. The drilling mud of claim  20 , wherein the drilling fluid further comprises a fluid loss additive selected from the group consisting of carboxymethyl cellulose, carboxyethyl cellulose, lignite, xanthan gum, starch, sodium polyacrylamide, hydroxy methyl cellulose, hydroxy ethyl cellulose, guar gum, hydroxy propyl guar and hydroxy ethyl guar. 
     
     
       23. The drilling mud of claim  20 , wherein the alkali metal phosphate is selected from the group consisting of mono-, di-, and tri-sodium phosphate, mono-, di-, and tri-potassium phosphate, mono-, di-, and tri-cesium phosphate, and sodium acid pyrophospate and the borate is boriborate. 
     
     
       24. The drilling mud of claim  20 , wherein the drilling fluid further comprises borax. 
     
     
       25. The drilling mud of claim  14 , wherein the drilling fluid further comprises a C 1-24  saturated or C 2-24  unsaturated carboxylic acid source. 
     
     
       26. The drilling mud of claim  25 , wherein the drilling fluid further comprises a gel. 
     
     
       27. The drilling mud of claim  25 , wherein the drilling fluid further comprises a fluid loss additive selected from the group consisting of carboxymethyl cellulose, carboxyethyl cellulose, lignite, xanthan gum, starch, sodium polyacrylamide, hydroxy methyl cellulose, hydroxy ethyl cellulose, guar gum, hydroxy propyl guar and hydroxy ethyl guar. 
     
     
       28. The drilling mud of claim  26 , wherein the drilling fluid further comprises a surfactant and/or a preservative. 
     
     
       29. The drilling mud of claim  14 , wherein the drilling fluid further comprises a saturated or unsaturated carboxylic acid source, and at least one of an alkali metal phosphate, borate and sodium silicate. 
     
     
       30. The drilling mud of claim  29 , wherein the drilling fluid further comprises a gel. 
     
     
       31. The drilling mud of claim  29 , wherein the drilling fluid further comprises a fluid loss additive selected from the group consisting of carboxymethyl cellulose, carboxyethylcellulose, lignite, xanthan gum, starch, sodium polyacrylamide, hydroxy methyl cellulose, hydroxy ethyl cellulose, guar gum, hydroxy propyl guar and hydroxy ethyl guar. 
     
     
       32. The drilling mud of claim  29 , wherein the drilling fluid further comprises a surfactant and/or a preservative. 
     
     
       33. A drilling mud of claim  13 , wherein the drilling mud comprises 0.25 to 2.0 volume percent of the drilling fluid. 
     
     
       34. A drilling mud of claim  14 , wherein the drilling mud comprises 0.25 to 2.0 volume percent of the drilling fluid. 
     
     
       35. A drilling mud of claim  17 , wherein the drilling mud comprises 0.25 to 2.0 volume percent of the drilling fluid. 
     
     
       36. A drilling mud of claim  20 , wherein the drilling mud comprises 0.25 to 2.0 volume percent of the drilling fluid. 
     
     
       37. A drilling mud of claim  25 , wherein the drilling mud comprises 0.25 to 2.0 volume percent of the drilling fluid. 
     
     
       38. A drilling mud of claim  29 , wherein the drilling mud comprises 0.25 to 2.0 volume percent of the drilling fluid. 
     
     
       39. A method of reducing the cost of repair of a mud motor comprising using the salt water drilling mud of claim I as the drilling mud in a drilling operation. 
     
     
       40. A method of reducing the cost of repair of a mud motor comprising using the salt water drilling mud of claim  14  as the drilling mud in a drilling operation. 
     
     
       41. A method of reducing the operating pressure of a mud motor for circulating a drilling mud in a borehole comprising using the salt water drilling mud of claim  1 . 
     
     
       42. A method of reducing the operating pressure of a mud motor for circulating a drilling mud in a borehole comprising using the salt water drilling mud of claim  14 . 
     
     
       43. The method of claim  12 , wherein each of the modules of the drilling fluid additive further comprises glycerol, and an acid selected from phosphoric acid, boric acid and mixtures thereof.